Mattress Transporting Roller Box

ABSTRACT

A roller box assembly includes a roller box and a bedding product contained in the roller box. The roller box includes a cardboard box portion, a pair of fixed-axis wheels, and a handle. The fixed-axis wheels are disposed along a corner edge of a bottom portion of the box portion. The handle portion is attached to the top portion of the box portion. In one embodiment, the bedding product is a mattress that has been compressed and rolled into a cylinder shape. A retail customer can purchase the bedding product at a retail store, and can then transport the purchased product out of the store by pulling the box from the handle such that the box rolls on its rollers.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of, and claims priority under 35U.S.C. §120 from, nonprovisional U.S. patent application Ser. No.11/541,368 entitled “Mattress Transporting Roller Box,” filed on Sep.30, 2006, the subject matter of which is incorporated herein byreference. Application Ser. No. 11/541,368, in turn, is a continuationof, and claims the benefit under 35 U.S.C. §119 from, Chinese PatentApplication No. 200620055540.0, filed in China on Feb. 23, 2006, thecontents of which are also incorporated herein by reference.

TECHNICAL FIELD

The described embodiments relates to a roller box, and more particularlyto a roller box assembly for retaining and transporting a beddingproduct.

BACKGROUND INFORMATION

In the retail sale of mattresses, it can be difficult for the customerto purchase and take home a mattress due to the size and weight of themattress. The difficulty and cost of scheduling a delivery to thecustomer's home can serve as an impediment to a sale. It is, however,now known to compress a mattress and to provide the mattress to thecustomer in a compressed state in a box at the retail store.

FIG. 1 (Prior Art) is a perspective view of the top 1 and the sides 2and 3 of one such box 4. FIG. 2 is a perspective view of the bottom 5and sides 2 and 3 of the box 4 of FIG. 1. Box 4 contains a compressedand rolled foam mattress. Box 4 has a substantially cubical shape thatis about three feet on a side. The customer may extend his/her armsforward, and push on the top surface of the box, thereby causing the boxto roll on four casters 6-9 in front of the customer. In this way, thecustomer who has purchased the mattress can roll the mattress in box 4out of the store and to the customer's vehicle. Provided that thecustomer has an adequately large vehicle, the customer can transport themattress home in its box without having to schedule a delivery and towait for delivery of the mattress. Improvement in this shipping anddelivery mechanism is desired.

SUMMARY

A roller box assembly includes a roller box and a bedding productcontained in the roller box. The roller box includes a box portion, apair of fixed-axis wheels, and a handle. In one embodiment, the boxportion is made of cardboard. The fixed-axis wheels are disposed along acorner edge of a bottom portion of the box portion. The handle portionis attached to the top portion of the box portion. Each of thefixed-axis wheels has an axis that extends in a line. The line isdisposed between the plane of the upper surface of the top portion andthe plane of the bottom surface of the bottom portion. The line isparallel to the two planes, and does not intersect either plane. In oneembodiment, the bedding product is a coil form innerspring mattress thathas been compressed and placed in a first bag. The compressed and baggedmattress is then rolled into a cylindrical shape. The resulting rolledstructure is taped to hold the cylindrical shape, and is placed in acylindrical-shaped second bag to prevent the rolled mattress fromunrolling and putting undue outward pressure on the box portion.

The roller box is used in a novel method whereby a retail customerpurchases a mattress in a retail store, and then transports the mattressout of the retail store by pulling on the handle of the roller boxassembly and thereby rolling the roller box out of the store on the twofixed-axis wheels of the roller box.

Further details and embodiments are described in the detaileddescription below. This summary does not purport to define theinvention. The invention is defined by the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, where like numerals indicate like components,illustrate embodiments of the invention.

FIGS. 1-2 (Prior Art) are perspective views of a box that contains acompressed foam mattress.

FIG. 3 is a perspective view of a top portion of a box portion of aroller box assembly in accordance with one novel aspect.

FIG. 4 is a perspective view of a bottom portion of the box portion ofthe roller box assembly of FIG. 3.

FIG. 5 is a perspective view of the bottom portion of the box portion ofthe roller box assembly of FIG. 3, showing the first and second bottomflaps opened to reveal the bottom insert portion.

FIG. 6 is a view the roller box of the roller box assembly of FIG. 3,when the roller box is partially disassembled to reveal how the bottominsert portion is attached to the first sidewall of the box portion.

FIG. 7 is a perspective view of one of the wheels of the roller boxassembly.

FIG. 8 is a side view of the roller box assembly of FIG. 3.

FIG. 9 is a perspective view of the bedding product that is contained inthe box portion of the roller box assembly of FIG. 3.

FIG. 10 is a perspective view of the compressed and rolled mattress ofthe bedding product of the roller box assembly of FIG. 3.

DETAILED DESCRIPTION

FIG. 3 is a top-down perspective diagram of a top portion 100 of a boxportion of a roller box assembly in accordance with one novel aspect.FIG. 4 is a perspective view of a bottom portion 101 of the box portionof the roller box assembly of FIG. 3. The roller box assembly includes aroller box 102 and a bedding product (not shown, see FIGS. 9 and 10)that is disposed within the roller box. Roller box 102 includes the boxportion, a first fixed-axis wheel 107, a second fixed-axis wheel 108,and a handle 109. The box portion includes the top portion 100, foursidewalls 103-106, and the bottom portion 101. A linearly-extendingcorner edge 110 is formed where the bottom portion 101 meets sidewall103. Each of the fixed-axis wheels 107 and 108 is disposed along thecorner edge 110 such that the axes of wheels 107 and 108 aresubstantially collinear and extend parallel to corner edge 110. Topportion 100 includes four flaps, where each of the flaps extends fromone of the four sidewalls. The flaps are folded over the enclosed volumeof the box to form top portion 100. In FIG. 3, a piece of tape 111 isillustrated holding top flaps 112 and 113 down and in place. The othertwo top flaps 114 and 115 are not illustrated because they are coveredby top flaps 112 and 113 in the view of FIG. 3.

Bottom portion 101 includes a first bottom flap 116, a second bottomflap 117, and a bottom insert portion 118. First bottom flap 116 extendsfrom sidewall 104. Second bottom flap 117 extends from sidewall 105. Thefirst and second bottom flaps 116 and 117 are folded over and into thesame plane so as to form a planar bottom surface of the box portion.Bottom insert portion 118 (also referred to as the “inner plate” of thebottom portion) may be made of a cardboard material that is more rigidthan the plurality of sidewalls. In FIG. 4, a piece of tape 119 isillustrated holding first and second bottom flaps 116 and 117 foldedover and in place.

FIG. 5 is a perspective diagram that shows the tape 119 removed and thatshows the first and second bottom flaps 116 and 117 opened to revealbottom insert portion 118. Bottom insert portion 118 has a bottomsurface disposed in a first plane. This first plane is parallel to theplanar bottom surface of the box formed by the first and second flaps116 and 117 when flaps 116 and 117 are folded down. Notches 120 and 121are provided in flaps 117 and 116, respectively, to accommodate and fitaround wheels 107 and 108, respectively. Tab extension portions 122 and123 of sidewall 106 fit into accommodating receiving slits 124 and 125in bottom insert portion 118. A top surface (not shown) of bottom insertportion 118 forms the actual inside bottom surface of the roller box.

FIG. 6 is a view of roller box 102 when it is partially disassembled. Inthe view of FIG. 6, the flaps of the top and bottom portions are opened,and a glued joint between sidewalls 104 and 106 is broken such that thevarious panels (103-106, 112-117) can be unfolded. In the presentlydescribed embodiment, the panels 103-106 and 112-117 are different partsof a single piece of cardboard as illustrated in FIG. 6. A lip extension126 is provided along the edge of sidewall 106 for attaching sidewall106 to sidewall 104.

In the view of FIG. 6, the bottom insert portion 118 is shown attachedto sidewall 103. FIG. 7 is a perspective view of wheel 107. Wheel 108 isidentical to wheel 107. Wheel 107 is made of hardened plastic andincludes a wheel 127, a wheel housing 128, and an axle 129. Wheelhousing 128 includes two attachment extensions 130 and 131, each ofwhich is provided with a hole for receiving a retaining bolt. Attachmentextension 130 forms a flat surface that extends in a first plane, andattachment extension 131 forms a flat surface that extends in a secondplane, where the two planes are perpendicular to each other. Bottominsert portion 118 includes folded up edge portions 132 and 133 forengaging sidewalls 103 and 106, respectively. Bottom insert portion 118is attached to sidewall 103 by placing the attachment extension 130 ofwheel 107 on the underside side (in the position illustrated) of panel103. The threaded shaft of a bolt is extended up through the hole inattachment portion 130, through a hole in sidewall 103, through a holein edge portion 132, and up through a hole in a rigid strip member 134.A nut 135 engages threads on the shaft of the bolt such that a washer onthe top side (as illustrated) of rigid strip member 134 sandwiches rigidstrip member 134, edge portion 132, and sidewall 103 between the washerand attachment extension 130. The combination of edge portion 132 andrigid strip member 134 serve to distribute the force due to the weightof the box and its contents from wheels 107 and 108 into sidewall 103. Asecond rigid strip member 136 and sets of nuts and bolts attach thewheels 107 and 108 to the base portion 137 of bottom insert portion 118as illustrated. A third rigid strip 138 and sets of nuts and boltsattach the handle 109 to top flap 112 as illustrated.

FIG. 8 is a side view of the roller box assembly of FIG. 3. Distance Abetween the plane 139 of the upper surface of top portion 100 and theplane 140 of the bottom surface of bottom portion 101 is at least threefeet in this embodiment. The axis 141 of wheels 107 and 108 extends in aline parallel to plane 139 and parallel to plane 140 such that the lineis located between the two planes but does not intersect either plane.In the embodiment of FIG. 8, the line of axis 141 is also locatedbetween the vertically-extending plane of sidewall 103 and thevertically-extending plane of sidewall 106.

FIG. 9 is a diagram of bedding product 142 that is contained in rollerbox 102 of the roller box assembly of FIG. 3. Bedding product 142 inthis example includes a compressed and rolled up pocket coil innerspringmattress 143 and a cylindrical-shaped bag 144. In one example, themattress is placed in a first bag 145, and the mattress is compressedbetween two surfaces so that it appears as a flattened mattress disposedin the first bag. Air is prevented from reentering the first bag,thereby facilitating keeping the mattress in its flattened compressedstate. The flattened compressed mattress in first bag 145 is rolled intoa cylinder form. Pieces 146 and 147 of tape are applied to prevent theroll from unrolling. The result appears as illustrated in FIG. 10. Theroll of FIG. 10 is then placed in second bag 144. Second bag 144 has acylindrical-shape that has a diameter substantially equal to the widthof the panels 103-106. Second bag 144 has a drawstring (not shown) forpulling the upper end of the bag closed. The resulting bedding product142 is illustrated in FIG. 9. Bedding product 142 is slid into the opentop of the roller box, and the flaps 112-115 are folded down and tapedin place so that the roller box assembly appears as illustrated in FIG.3. For additional information on one example of bedding product 142,see: U.S. patent application Ser. No. 11/458,359, filed Jul. 18, 2006,entitled “Method Of Packaging An Innerspring Mattress”, published asU.S. Patent Application Pub. No. 2007/0204566 (the subject matter ofwhich is incorporated herein by reference).

Although certain specific embodiments are described above forinstructional purposes, the teachings of this patent document havegeneral applicability and are not limited to the specific embodimentsdescribed above. Accordingly, various modifications, adaptations, andcombinations of various features of the described embodiments can bepracticed without departing from the scope of the invention as set forthin the claims.

1-13. (canceled)
 14. A method comprising: retaining a bedding product ina roller box, wherein the roller box has two fixed-axis wheels disposedalong a corner edge of a bottom portion of the roller box, and whereinthe roller box has a handle attached to a top portion of the roller box.15. The method of claim 14, wherein the roller box has a plurality ofcardboard sidewalls.
 16. The method of claim 15, wherein the beddingproduct is a roll of material that is contained in a cylindrical-shapedbag.
 17. The method of claim 15, wherein the bedding product is acompressed and rolled innerspring mattress, and wherein the compressedand rolled innerspring mattress is contained in a cylindrical-shapedbag.
 18. The method of claim 14, further comprising: supplying thebedding product in the roller box to a retail customer.
 19. The methodof claim 14, further comprising: encouraging a retail customer totransport the bedding product out of a retail store by rolling theroller box on its two fixed-axis wheels. 20-21. (canceled)
 22. Themethod of claim 14, wherein the bedding product is a mattress, andwherein the roller box further comprises: a box portion having thebottom portion, a top portion, and a plurality of sidewalls, wherein thebottom portion meets a first of the sidewalls to define the corner edge,wherein the box portion has a height and a width, wherein the topportion has an upper surface, and the bottom portion has a bottomsurface, wherein the two fixed-axis wheels have a common and fixed axisof rotation between the upper surface and the bottom surface thatextends parallel to the upper surface and to the bottom surface, andwherein the mattress is rolled into a cylindrical shape with a diametersubstantially equal to the width of the box portion and a lengthsubstantially equal to the height of the box portion.
 23. The method ofclaim 14, wherein the bedding product is a mattress, and wherein theroller box further comprises: a cardboard box having a height of atleast three feet and a width, wherein the cardboard box contains themattress rolled into a cylindrical shape with a diameter substantiallyequal to the width and a length substantially equal to the height,wherein a top portion of the cardboard box has an upper surface thatextends in a first plane, wherein a bottom portion of the cardboard boxhas a bottom surface that extends in a second plane, wherein each of thetwo fixed-axis wheels has an axis of rotation that extends in a line,wherein the line is parallel to the first and second planes and does notintersect either the first plane or the second plane, wherein the lineextends between the first and second planes, and wherein the handleextends outside the cardboard box from the upper surface.
 24. A methodcomprising: retaining a mattress in a roller box, wherein the roller boxcomprises: a box portion having a top portion, a bottom portion, and aplurality of sidewalls, wherein the box portion has a height and awidth, wherein the top portion has an upper surface, and the bottomportion has a bottom surface, and wherein the bottom portion meets afirst of the sidewalls to define a corner edge of the box portion; twowheels disposed along the corner edge, wherein the two wheels have acommon and fixed axis of rotation between the upper surface and thebottom surface that extends parallel to the upper surface and to thebottom surface; and a handle attached to the top portion of the rollerbox, wherein the mattress is rolled into a cylindrical shape with adiameter substantially equal to the width of the box portion and alength substantially equal to the height of the box portion.
 25. Themethod of claim 24, wherein the mattress is contained in acylindrical-shaped bag.
 26. The method of claim 24, wherein the mattressis contained in a bag from which air has been evacuated.
 27. The methodof claim 24, further comprising: supplying the mattress in the rollerbox to a retail customer.
 28. The method of claim 24, furthercomprising: encouraging a retail customer to transport the mattress outof a retail store by rolling the roller box on its two wheels.
 29. Themethod of claim 24, wherein the mattress is taped to prevent themattress from unrolling.
 30. The method of claim 24, wherein themattress is a compressed innerspring mattress.
 31. A method comprising:retaining a mattress in a roller box, wherein the roller box comprises:a box portion having a top portion, a bottom portion, and a plurality ofsidewalls, wherein the bottom portion meets a first of the sidewalls todefine a corner edge of the box portion, wherein the box portion has aheight and a width, wherein the top portion has an upper surface thatextends in a first plane and the bottom portion has a bottom surfacethat extends in a second plane; and two wheels disposed along the corneredge, wherein the two wheels have a common and fixed axis of rotationthat extends in a line, wherein the line is parallel to the first andsecond planes and does not intersect either the first or second plane,wherein the line extends between the first and second planes, andwherein the mattress is rolled into a cylindrical shape with a diametersubstantially equal to the width of the box portion and a lengthsubstantially equal to the height of the box portion.
 32. The method ofclaim 31, wherein the roller box further comprises: a handle attached tothe top portion of the box portion.
 33. A method comprising: retaining amattress in a roller box, wherein the roller box comprises: a boxportion having a top portion, a bottom portion, and a plurality ofsidewalls, wherein the box portion has a height and a width, and whereinthe bottom portion meets a first of the sidewalls to define a corneredge of the box portion; two fixed-axis wheels disposed along the corneredge; and a rigid strip member, wherein the rigid strip member extendslengthwise parallel to the corner edge, wherein each of the twofixed-axis wheels is coupled to the rigid strip member, wherein therigid strip member is immovably attached to a single one of theplurality of sidewalls, and wherein the mattress is rolled into acylindrical shape with a diameter substantially equal to the width ofthe box portion and a length substantially equal to the height of thebox portion.
 34. The method of claim 33, wherein the mattress is acompressed innerspring mattress.
 35. The method of claim 33, furthercomprising: supplying the mattress in the roller box to a retailcustomer.